Hurricane panel

ABSTRACT

A hurricane panel configured to cover a building opening that is made of a geocomposite having an impermeable core and surrounded by both sides with batting, and anchoring means for attachment to a building.

PRIOR RELATED APPLICATIONS

This application claims priority to 60/954,567 (incorporated byreference in its entirety) filed Aug. 7, 2007.

FEDERALLY SPONSORED RESEARCH STATEMENT

Not applicable.

REFERENCE TO MICROFICHE APPENDIX

Not applicable.

FIELD OF THE INVENTION

The invention relates to flexible panels that can be used to protectstructures from hurricane and wind damage.

BACKGROUND OF THE INVENTION

During hurricanes and other high wind storms, windows are often damaged,and the breach can cause great damage to the structure. Hurricaneshutters are often used to protect building openings from the hazards ofwind-blown debris and pressure changes. These are usually made from arigid material, such as aluminum, wood and sometimes plastic. However,shutters are expensive, cumbersome and heavy. Plywood is inexpensive andis often used as a window covering during storms. But, althoughinexpensive, plywood is not durable, is awkward to store, difficult toput up, and does not provide optimal protection.

From our experience in the environmental and petrochemical industry, webelieved that there were a variety of flexible liner products availablefrom landfill preparation or the petrochemical industry that couldprovide hurricane protection for homes and businesses in a more costeffective manner.

Hurricane panels made of fabric are available. These panels aremanufactured and installed to provide the protection required by thebuilding codes of particular geographic areas. The building codes arebased on standardized testing to meet certain standards of strength andintegrity.

For example, flexible hurricane window panels are described in U.S. Pat.No. 6,865,852, U.S. Pat. No. 6,325,085 U.S. Pat. No. 6,176,050, U.S.Pat. No. 6,886,299, and US2004159345 by TARGUS INTERNATIONAL™. Thesepatents describe a protective barrier device formed of a flexible meshmaterial having a burst strength greater than 61.3 psi and an intersticesize constructed and arranged to prevent passage of wind-borne objectsgreater than about 3/16 inch diameter, whereby the protective barrier isplaced in front of a window, and secured thereto. Preferably, theprotective barrier device is a textile formed from synthetic threads,for example, polypropylene.

U.S. Pat. No. 6,341,455 by Gunn describes flexible material used tocover a window whereby cylinder or roller bar is used to deploy thecovering in a manner analogous to a shade. However, the roller bar isdifficult to fabricate and subject to jamming.

U.S. Pat. No. 6,296,039, U.S. Pat. No. 6,341,639, and U.S. Pat. No.6,431,250 by WAYNE DALTON™ describe a curtain system covering an openingin a building, but again the window attachment mechanism is cumbersome.Another cumbersome attachment means is described in U.S. Pat. No.6,851,464, also by WAYNE DALTON™. U.S. Pat. No. 6,886,300, also by WAYNEDALTON™, requires that the panel edges be inserted into channels, andthe fabric material stretched between the channels.

What is needed in the art is a panel with sufficient strength that canbe applied to a building in a simple manner with readily availablehardware.

SUMMARY OF THE INVENTION

The invention generally relates to methods, kits and panels forprotecting a window in a building using a geocomposite membrane havingreinforced edges and a core of impermeable plastic surrounded on bothsides by batting and having a puncture resistance of 250 lbs whenmeasured by ASTM D-4833. The geocomposite membrane can be anchored overthe window with any anchoring and attachment means, including grommetsand fasteners. In preferred embodiments, the method also employs adeflection inhibitor comprising at least one elongated member so placedas to span said building opening and placed underneath said geocompositemembrane, and the deflection inhibitor can be telescoping. In otherembodiments, a rectangular strip is used on the edges further contributeto the attachment of the panel over the window. The rectangular stripalso contributes to edge reinforcement since it spreads the attachmentload over more of the edge of the panel.

We designed a much stronger flexible panel than has been used in thepast. The panel has an impermeable core (e.g., it lacks interstices),and is surrounded by batting layers on each side, giving the panelgreatly increased strength, yet keeping it flexible for easy storage. Wecalled the panel a Weathervest™ and a cross-section in FIG. 1 shows theimpermeable core 1 and batting 3.

The panel can be mounted directly to the building using readilyavailable hardware, such as nails, bolts, hooks, screws, tapons,washers, clamps and the like, and as appropriate for the buildingconstruction. Alternatively, the panel can be attached with anattachment strip that allows fewer direct attachments to the buildingand spreads the load. A deflection limiter can be attached under thepanel to limit the deflection caused by a hurricane-blown missile. Theattachment strip and deflection limiter are preferably aluminum forlightweight strength and resistance to corrosion, however, othermaterials can be used, including sufficiently strong plastic or resin,iron, wood, metals, and the like. In one embodiment, the attachmentstrip can be affixed to the geocomposite membrane, and if so it ispreferred that the strips be of shorter length with some space betweenstrips so as to allow for easy folding of the panel during storage.

The attachment strip and deflection limiter can be the same, or aspecial deflection limiter can be designed to be telescoping, forexample. Where the attachment strip and deflection limiter are the same,they can be made available in a few standard sizes, allowing the homeowner to select the sizes appropriate for the building windows.

The edges of the panel can be reinforced for maximum strength at thepoint of attachment to the building. The reinforcement can be a flexiblestrip sewn or glued to the edges (e.g., a selvage), but for ease ofmanufacture and cost the panel may be folded back on itself and attachedwith grommets, glue, stitching and the like. In one embodiment thegrommets are attached approximately 2 inches from the edge of thematerial.

Grommets Size range from 3/16″ (00), ¼″ (0), 9/32″ (1), ⅜″ (2), 7/16″(3), ½″ (4), ⅝″ (5), 13/16″ (6), 15/16″ (7), 1 1/16″ (8), 1½″ (10), 19/16″ (12). Grommet size can be adjusted to fit a variety of bolt, screwor fastener configurations.

The panel is light, can be rolled up or folded, stored easily, and usedmultiple times. If desired, permanent yet discreet fasteners can beadded to the house, allowing quick set up after the first use. Forexample, a hook or eye bolt is added to the house, and short stretchycords (such as a bungy cord) can be used to hold the panel.Alternatively, a bolt can be added to the house, and the panel fittedover the bolt and a nut used to fasten the panel. In yet anotheralternative, a releasable clamp can be added to the house, that in theopen position allows easy mounting of the panel, but when closedtightens the panel across the opening.

Our testing shows that the panel can take multiple hits fromhurricane-blown missiles with no damage. Another benefit is that thepanel is impermeable to wind and water.

The preferred geocomposite panel is constructed with something similarto the CANAL ³ 123012™, which has two layers of 12 oz/square yardnonwoven polyester batting bonded to 30 mils of an EVA geomembrane. Thismaterial has a grab tensile strength of approximately 500 lbs, aTrapezoid Tear Strength of 150 lbs, and a Puncture Strength of over 250lbs. These characteristics provide enough strength to resist debrispuncturing and tear forces generated by a hurricane. However, othermaterials can be used, provided the basic structure and a PunctureStrength of over 250 lbs are maintained. Other geomembrane equivalentsare listed in Table 1.

TABLE 1 Geomembrane equivalents. HUESKER CARTHAGE US CANAL³ ™ MIRAFI ™WEBTEC ™ MILLS ™ AMOCO ™ SYNTHETIC ™ LINQ ™ FABRICS ™ 135 N NO3 FX-30HS4535 311 125 EX 80NW 140 NL NO4 FX-35HS 4545 351 125 EX 90NW Mirapave400 OL FX-380L 4599 381 130 EX 90P Petromat 140 NC SD FX-40HS 4546 401130 EX 115NW 140 N NO4.5 FX-45HS 4547 451 140 EX 120NW 160 N NO6 FX-60HS4551 601 150 EX 160NW 170 N NO7 FX-70HS 4552 701 180 EX 180NW 180 N NO8FX-80HS 4553 801 225 EX 205NW 1100 N NO10 FX-100HS 4510 1001 250 EX270NW 8208 1120 N NO12 FX-120HS 4512 1201 275 EX 300NW 123012 1160 NNO16 FX-160HS 4516 1601 350 EX 380NW — — FX-22 — 100ST — 100 500 X GSFX-55 2002 200ST GTF 200 200 550 X GS-250 FX-60 2004 250ST GTF 250 250600 X HD FX-66 2006 300ST GTF 300 315 HP 570 — FX-400MF 2044 4 × 4 GTF570 4800 FW 700 EP Carthage 6% 1199 Geotex 104F GTF 400 670 HP 550 —Carthage 10% — — — 840 HD FW 402 — Carthage 15% 1198 Geotex 111F GTF400EO 1540 FW 500 — Carthage 30% — Geotext 117F — 3040

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1. Cross section of geomembrane composite showing core (1) andbatting (3).

FIG. 2 Top view of panel (5), showing reinforced edge (7) and grommets(9), together with single attachment strip (11), also having openings(13) at the same spacing as the grommets (not to scale).

FIG. 3. Telescoping deflection limiter showing smaller member (17)inside larger member (15) and openings (19) at end (not to scale).

FIG. 4. End views of three deflection limiter embodiments (not toscale).

FIG. 5. Deflection limiters in use on window (100) (not to scale).

FIG. 6. Panel (5) showing grommets (9) approximately two inches from theedge of the panel. Grommets (9) are only placed along two edges of thepanel and the panel requires no additional reinforcing.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The invention provides a novel use of a geocomposite that hastraditionally been used as a chemical pond liner. The material isextremely tough, yet flexible and affordable. Further, it can beattached with readily available hardware, or can be attached withattachment strips. In a preferred embodiment, it is combined with adeflection limiter.

In one embodiment, the invention is a hurricane panel made of ageocomposite membrane shaped to cover a building opening. Thegeocomposite membrane has a core of impermeable plastic surrounded onboth sides by batting and a puncture resistance of 250 lbs when measuredby ASTM D-4833. At least two edges of the membrane have anchoring meansfor attaching said panel to said building so as to cover said buildingopening, and preferably all edges have anchoring means.

In another embodiment, the protective building panel comprises ageocomposite membrane having a core of impermeable plastic surrounded onboth sides by batting and having a puncture resistance of 250 lbs whenmeasured by ASTM D-4833. The geocomposite membrane is configured tocover a building opening. Further, a plurality of grommets are placed 2inches from the edge of the panel on opposing sides of the panel. In usethe panel further comprises at least one elongated attachment striphaving openings at the same spacing. The attachment strip is placed overthe reinforced edge, so that the openings and grommets are aligned. Thepanel is attached to the building by at fastener, passing through saidopenings and grommets and connecting to said building. Either embodimentcan be combined with deflection limiters that span the opening,minimizing the deflection of the panel when struck by debris.

FIG. 2 shows the panel (5) with a two inch edge (7) and grommets (9) sixinches apart. A single attachment strip (11) with openings (13) is shownbeside the panel. In practice, several of these would be used to attachthe panel to the building by lining up the grommets and attaching thepanel and the strip to the building using standard hardware.

The batting of the geocomposite membrane can be nonwoven or woven, orcombinations thereof. The batting materials can include polyester,polyolefin, cotton, air-fluffed wood fiber, and the like. The battingcan also comprise mixtures of resins, one of which is a low melt fiberthat can be used to impart further strength to the batting when heatset. The core can be any sufficiently strong plastic, including HDPE,LDPE, MDPE, LLDPE, EVA, composites, reinforced plastics and the like.Various combinations are possible, provided that the three layerstogether maintain the requisite puncture resistance. Suitablegeomembrane composites include CANAL ³ 123012™ available from HUESKERINC.™, as well as other commercially available plastic composites. Thebatting can also be covered with a polymer or resin.

EXAMPLE 1 First Attempt

In our first attempt to devise a flexible window covering we tried areinforced polypropylene membrane from CARLISLE™. The membrane wasprepared by doubling the edges and heat welding. Grommets were spaced atapproximately 1 ft apart. The initial material was taken to anindependent laboratory and tested by firing a 2″×4″ board at 50 ft/secat the panel. The material failed the test by tearing at the grommets.It was decided that the grommet spacing was too wide, and that thetensile strength and puncture resistance of the fabric were not strongenough. A stronger material was needed.

EXAMPLE 2 Material Selection

In our second attempt, we searched for a much stronger commerciallyavailable material. We chose a geocomposite with nonwoven batting onboth sides for added strength, but having a core of EVA geomembrane inthe center. We believed that batting would add considerable strengthwhere it was needed, on the outside of the panel, and the interior corerendered the entire panel completely water- and wind-proof.

Suitable materials were available in three different weights (CANAL ³8208™, CANAL ³ 165016™, and CANAL ³ 123012™ available from HUESKERINC.™). These materials are used for environmental applications,including canal liners, landfill cover liners, and wastewater lagoonliners, but have never been applied to house construction or ashurricane protection of buildings.

The three geocomposites were purchased, fabricated into panels andtested by an independent laboratory, as above. Two of the threegeocomposite panels failed the test tearing the material either atimpact or at the grommets from the force of the 2″×4″ hitting them. Theother geocomposite panel made from CANAL ³ 123012™ was shot five timesand passed the 2″×4″ test. From this, we have concluded that a puncturestrength of at least 250 lbs and a trapezoid tear strength of 150 lbsprovides sufficient strength and flexibility. Additionally, the materialmust be more flexible than the CANAL ³ 165016™ to prevent tearing by2″×4″ impacts.

CANAL ³ 123012™ is a geocomposite that consists of two (top and bottom)12 oz per square yard polyester nonwoven sheets bonded to 30 millimetersthickness of an EVA geomembrane. The CANAL ³ 123012™ is inert tobiological degradation and naturally encountered chemicals, alkalies,and acids. This material conforms to the nominal values listed in Table1 and provided by the manufacturer.

TABLE 2 Properties of Geomembranes Canal³ Canal³ 8208 123012 MASS PERUNIT AREA, oz/yd² (ASTM D-5261) 36 50 MEMBRANE THICKNESS, mils (ASTMD-5199) 20 30 GRAB TENSILE STRENGTH, lbs (MD) (ASTM D-4632) 300 500 GRABELONGATION, % (MD) (ASTM D-4632) >50 >50 TRAPEZOIDAL TEAR STRENGTH, lbs(ASTM D-4533) 100 (MD) 150 (MD) PUNCTURE STRENGTH, lbs (PIN 5/16) (ASTMD-4833) 175 250 PERMEABILITY, (ASTM D-4491) not measurable notmeasurable CANAL³ 123012 ™ was fabricated into prototype wind panels,and sent to another independent laboratory for cyclic wind pressureloading.

EXAMPLE 3 Testing

An independent laboratory performed testing on four (4) Weathervestpanels. The following tests were performed:

1) ASTM E 1886-02: Standard Test Method for Performance of ExteriorWindows, Curtain Walls, Doors and Storm Shutters Impacted by Missile(s)and Exposed to Cyclic Pressure Differentials.

2) ASTM E 1996-02: Standard Specification for Performance of ExteriorWindows, Glazed Curtain Walls, Doors and Storm Shutters Impacted by WindBorne Debris in Hurricanes.

3) TAS 202-94: Criteria for Testing Impact and Non Impact ResistantBuilding Envelope Components Using Uniform Static Air Pressure Loading.

The test specimens were 6′3″ wide by 9′0″ Weathervest™ fabricated fromCANAL ³ 123012. The edges were pierced with #4 grommets placed every 6inches. The grommets were 2 inches away from the edge of the panel. Witha 2 inch border and grommets at 6 inch intervals, it was not necessaryto further reinforce the edge of the panels. The prototypes wereinstalled into concrete masonry bucks using ¼″×2¼″ Tapcon anchors with1″ diameter washers along the top and the bottom edges. The anchors werelocated 2″ from the corners and 6″ on center thereafter and passedthrough the metal grommets in the fabric. No attachment strip was usedin the tests.

TABLE 3 Test Equipment Cannon: Steel pipe barrel utilizing compressedair to propel the missile Missile: 2″ × 4″ Southern Pine Timing Device:Electronic beam type Cycling Mechanism: Computer controlled centrifugalblower with electronic pressure measuring device Deflection MeasuringDevice: 24″ Caliper

The following results were recorded in the TAS 202-94, Static AirPressure Tests, at a design pressure of +31.6/−34.6 psf:

TABLE 4 Static Air Pressure Test Structural Loads Deflection Readings(inch) 50% of Test Pressure (+23.7 psf) 12.6 Maximum Deflection DesignPressure (+31.6 psf) 13.8 Maximum Deflection 50% of Test Pressure (−26.0psf) 16.9 Maximum Deflection Design Pressure (−34.6 psf) 18.1 MaximumDeflection Test Pressure (+47.4 psf) 15.4 Maximum Deflection TestPressure (−51.9 psf) 20.0 Maximum Deflection

Specimens tested for TAS 202-94 met the requirements of Section 1620 ofthe Florida Building Code, Building (2004). Tape and film were used toseal against air leakage during structural testing. The tape and filmdid not influence the results of the test.

The following results (Table 5) were recorded in the ASTM E 1896-2:Large Missile Impact Test with a missile weight of 8.8 lbs, length of8′1″, muzzle distance from test specimen of 17.0 ft. and average ambientair temperature of 91° F.

TABLE 5 Large Missile Impact Test Missile Velocity: 50.9 fps ImpactArea: Center of fabric Observations: Missile hit impact area, no damageDeflection: 9.6″ Results: Pass Missile Velocity: 50.1 fps Impact Area:Top right corner of fabric Observations: Missile hit impact area, nodamage Deflection: 3.3″ Results: Pass Missile Velocity: 50.1 fps ImpactArea: Top right corner of fabric Observations: Missile hit impact area,no damage Deflection: 2.9″ Results: Pass Missile Velocity: 51.4 fpsImpact Area: Center of fabric Observations: Missile hit impact area, nodamage Deflection: 5.7″ Results: Pass Missile Velocity: 51.7 fps ImpactArea: Lower left corner of fabric Observations: Missile hit impact area,no damage. Deflection: 2.0″ Results: Pass Missile Velocity: 51.8 fpsImpact Area: Center of fabric Observations: Missile hit impact area, nodamage. Deflection: 3.8″ Results: Pass

The following results (Table 6a) were recorded in ASTM E 1886-02: AirPressure Cycling test at a Design Pressure of +31.6/−34.6 psf:

TABLE 6a Air Pressure Cycling Test Maximum Deflec- Pressure Range Numberof Average Cycle tion at (psf) Cycles Time (sec.) Indicator (inch)Positive Pressure 6.3 to 15.8 3500 2.85 6.0 0.0 to 19.0 300 3.30 8.415.8 to 25.3 600 2.25 8.5 9.5 to 31.6 100 3.06 8.8 Negative Pressure10.4 to 34.6 50 4.55 17.0 17.3 to 27.7 1050 2.40 16.5 0.0 to 20.8 5011.60 14.8 6.9 to 17.3 3350 2.44 14.8

In a second test the following results (Table 6b) were recorded.

TABLE 6b Air Pressure Cycling Test Maximum Deflec- Pressure Range Numberof Average Cycle tion at (psf) Cycles Time (sec.) Indicator (inch)Positive Pressure 6.3 to 15.8 3500 2.09 8.3 0.0 to 19.0 300 5.27 8.515.8 to 25.3 600 2.41 10.5 9.5 to 31.6 100 3.70 11.0 Negative Pressure10.4 to 34.6 50 3.25 6.7 17.3 to 27.7 1050 2.46 7.8 0.0 to 20.8 50 6.279.0 6.9 to 17.3 3350 1.74 8.8 Permanent Set N/A

In another test at the following results (Table 6c) were recorded:

TABLE 6c Air Pressure Cycling Test Maximum Deflec- Pressure Range Numberof Average Cycle tion at (psf) Cycles Time (sec.) Indicator (inch)Positive Pressure 6.3 to 15.8 3500 2.06 5.8 0.0 to 19.0 300 6.21 7.115.8 to 25.3 600 3.77 7.8 9.5 to 31.6 100 3.67 11.0 Negative Pressure10.4 to 34.6 50 3.40 16.0 17.3 to 27.7 1050 2.50 15.8 0.0 to 20.8 506.19 14.3 6.9 to 17.3 3350 1.91 13.9 All tests were passed.

EXAMPLE 4 Deflection Inhibitor

One of the disadvantages of the impermeable core is that no wind passesthrough the panel, thus the full force of the wind or debris impacts thepanel and can cause significant deflection (as much as 20″ over a6′3″×9′ panel). There are buildings where such deflection would allowthe impact to reach and break the window. In such cases, we have added adeflection inhibitor to further protect the windows, which is merely anelongated strip that crosses over the window and is placed behind thepanel. Alternatively, or in combination, the anchoring means can beraised or thickened to place the panel further away from the window.

In a preferred embodiment, the elongated member is telescoping to fit arange of window sizes, and multiple elongated members are arrangedappropriately over the window in either parallel or crossed manner, orcombinations thereof. FIG. 3 shows a telescoping deflection inhibitor inwhere the smaller strip 17 fits closely inside the larger strip 15 andeach end has at least one opening 19.

End views of three embodiments are shown in FIG. 4. The first end viewis a telescoping deflection inhibitor, one elongated member 17 fittingclosely inside the other 15 and being held together with the edges 21and 23. The second end view shows a plain strip 25 having ridges 27 forstrength and the third view shows a reinforced deflection inhibitor withthree ridges 27 holding two strips 29 together. In its most simple form,however, the attachment strips are made available in various commonsizes and can also provide the deflection inhibitor function. Paralleland crossed patterns of use on window 100 are shown in FIG. 5.

1. A method of protecting a building opening, comprising a) obtaining ageocomposite membrane shaped to cover a building opening and having atleast one edge, said geocomposite membrane having a core of impermeableplastic surrounded on both sides by batting and having a punctureresistance of 250 lbs when measured by ASTM D-4833, wherein saidgeocomposite comprises anchoring means, b) attaching said geocompositemembrane to said building via said anchoring means so as to cover saidbuilding opening.
 2. The method of claim 1, wherein said anchoring meanscomprises grommets placed along the edges of said geocomposite membraneat a first spacing.
 3. The method of claim 2, further comprising adeflection inhibitor comprising at least one elongated member so placedas to span said building opening and placed underneath said geocompositemembrane.
 4. The method of claim 3, wherein the at least one elongatedmember is telescoping so as to fit a range of building opening sizes. 5.The method of claim 4, wherein said elongated member is aluminum.
 6. Themethod of claim 5 wherein the geocomposite membrane has two layers of 16oz/square yard nonwoven polyester batting bonded to 50 mils of an EVAgeomembrane.
 7. The method of claim 5 wherein the geocomposite membraneis CANAL ³ 123012™.
 8. A protective building panel, comprising ageocomposite membrane having a core of impermeable plastic surrounded onboth sides by batting and having a puncture resistance of 250 lbs whenmeasured by ASTM D-4833, said geocomposite membrane being configured tocover a building opening wherein a plurality of grommets are placedalong each edge at a first spacing, said grommets aligned to a fasteneraffixed to a building said fastener comprising a plurality ofattachments for passing through said aligned grommets.
 9. The protectivebuilding panel of claim 8, wherein the geocomposite membrane is CANAL ³123012™.
 10. A kit for protecting a building opening, said kitcomprising: a protective building panel, comprising a geocompositemembrane having a core of impermeable plastic surrounded on both sidesby batting and having a puncture resistance of 250 lbs when measured byASTM D-4833, said geocomposite membrane being reinforced along each edgeand having anchoring means along each edge.
 11. The kit of claim 10,further comprising attachment means that can operatively couple saidanchoring means and said building.
 12. The kit of claim 11, furthercomprising a deflection limiter that is an elongated member and havinganchoring means at each edge.
 13. The kit of claim 12 wherein thegeocomposite membrane has two layers of 16 oz/square yard nonwovenpolyester batting bonded to 50 mils of an EVA geomembrane.
 14. Themethod of claim 10 wherein the geocomposite membrane is CANAL ³ 123012™.15. The method of claim 12 wherein the geocomposite membrane is CANAL ³123012™.
 16. The kit of claim 12, wherein said deflection limiter is atelescoping elongated member.
 17. The kit of claim 12 wherein theanchoring means is a plurality of grommets.
 18. The kit of claim 17,wherein the grommets are placed about 6 inches apart.
 19. The kit ofclaim 18 further comprising one or more rectangular strips withanchoring means, said rectangular strips configured to as to contributeto the attachment means.
 20. The kit of claim 19 wherein saidrectangular strip and said deflection limiter comprise aluminum.